Portable active pneumatically powered ankle-foot orthosis

1. A portable active pneumatically powered ankle foot orthosis comprising:

a lower leg mount;

a foot bed pivotally configured to be coupled to said lower leg mount at or proximate to an ankle position;

at least one sensor for determining a phase of a user's gait;

a pneumatically powered rotary actuator coupled to said leg mount and to said foot bed, said rotary actuator being configured to receive power from a wearable fluid power source and to provide controlled force and/or resistance to aid or inhibit relative rotation of said foot bed and said lower leg mount; and

a controller for receiving data from said at least one sensor and controlling said pneumatically powered rotary actuator to actively assist gait of a user wherein said pneumatically powered rotary actuator comprises a pancake actuator having a front-to-back thickness significantly smaller than its diameter;

wherein said rotatable member comprises a shaft coupled to at least one vane;

wherein said pneumatically powered rotary actuator comprises a plurality of openings disposed within said outer housing such that each of the least one vane is disposed within one of the plurality of openings to divide each of the plurality of openings into first and second fluid chambers;

wherein said pneumatically powered rotary actuator further comprises:

first and second fluid inputs integrated with said outer housing; and

first and second fluid channels, wherein said first fluid channel fluidly couples said first fluid input with each of the first fluid chambers, and said second fluid channel fluidly couples said second input with each of the second fluid chambers.

2. The device of claim 1 , further comprising:

at least one actuated valve for connecting to said wearable fluid power source and controlling fluid flow to said pneumatically powered rotary actuator;

said at least one actuated valve being responsive to said controller.

3. The device of claim 2 , wherein said wearable fluid power source comprises a compact, wearable fluid power source coupled to said at least one valve and said pneumatically powered rotary actuator.

4. The device of claim 3 , wherein said wearable fluid power source comprises a container housing a compressible fluid.

5. The device of claim 2 , further comprising:

a pressure regulator coupled to said at least one actuated valve and to said pneumatically powered rotary actuator.

6. The device of claim 1 , wherein said lower leg mount and said foot bed comprise a rigid, lightweight material selected from the group consisting of carbon fiber, carbon composite, light metal, and plastic.

7. The device of claim 1 , wherein said controller is integrated with at least one of said lower leg mount and said foot bed;

wherein said controller comprises a microprocessor and a memory.

8. The device of claim 1 , further comprising:

an angle rotation sensor for sensing an angle between said lower leg mount and said foot bed.

9. The device of claim 1 , wherein said at least one sensor comprises at least one force sensor coupled to said foot bed for receiving a force applied to at least one portion of the foot bed and generating a signal.

10. A portable active pneumatically powered ankle foot orthosis comprising:

a lower leg mount;

a foot bed pivotally configured to be coupled to said lower leg mount at or proximate to an ankle position;

at least one sensor for determining a phase of a user's gait;

a pneumatically powered rotary actuator coupled to said lower leg mount and to said foot bed, said pneumatically powered rotary actuator being configured to receive power from a wearable fluid power source and to provide controlled force and/or resistance to aid or inhibit relative rotation of said foot bed and said lower leg mount, wherein said pneumatically powered rotary actuator comprises an outer housing, a rotatable member disposed within said outer housing, and at least one valve integrated with said pneumatically powered rotary actuator; and

a controller for receiving data from said at least one sensor and controlling said pneumatically powered rotary actuator by controlling said at least one valve to actively assist the user's gait, wherein said pneumatically powered rotary actuator comprises a pancake actuator having a front-to-back thickness significantly smaller than its diameter;

wherein said rotatable member comprises a shaft coupled to at least one vane;

wherein said pneumatically powered rotary actuator comprises a plurality of openings disposed within said outer housing such that each of the least one vane is disposed within one of the plurality of openings to divide each of the plurality of openings into first and second fluid chambers;

wherein said pneumatically powered rotary actuator further comprises:

first and second fluid inputs integrated with said outer housing; and

first and second fluid channels, wherein said first fluid channel fluidly couples said first fluid input with each of the first fluid chambers, and said second fluid channel fluidly couples said second input with each of the second fluid chambers.

11. The ankle foot orthosis of claim 10 , wherein said at least one valve comprises at least one of a solenoid valve and a proportional valve.

12. The ankle foot orthosis of claim 10 , further comprising:

a silencer disposed at least partially within said outer housing.

13. The ankle foot orthosis of claim 10 , further comprising:

a front cover attached to and at least partially covering said outer housing.

14. The ankle foot orthosis of claim 13 , further comprising:

an angle sensor integrated with said pneumatically powered rotary actuator;

wherein said angle sensor comprises a rotary encoder coupled to said front cover.

15. The ankle foot orthosis of claim 10 , wherein said rotary actuator and said controller are fixedly coupled to a surface of a support structure to provide a subassembly;

wherein the subassembly is coupled to said lower leg mount;

wherein said rotary actuator, said controller, and said at least one valve are integrated on the subassembly.

16. The ankle foot orthosis of claim 15 , wherein said controller comprises:

a circuit board disposed on a surface of the strut;

a processor disposed on said circuit board; and

at least one of an input port and an output port disposed on said circuit board;

wherein said circuit board is sized to fit within the surface of the strut.

17. The ankle foot orthosis of claim 10 , further comprising a strut coupling said lower leg mount to said pneumatically powered rotary actuator.